the customer magazine of andritz pulp & paper issue 12005 · the customer magazine of andritz...

The customer magazine of Andritz Pulp & Paper Issue 1— 2005

Developing the "perfect chip" at Wisaforest — Page 20

2 FiberSpectrum Issue 1 — 2005

Contents

M A G A Z I N E

FiberSpectrum is published by:

Andritz AGStattegger Strasse 18A-8045 Graz, AustriaTel: +43 316 6902 [email protected]

Managing Editor:Mia [email protected]

Editor:Robert [email protected]

Editorial Team:Bjørn HansenRegina EdelmayerMia Passi

Contributing Writers:Leif LindbergRobert PuhrRobert RyanMartin Swayne

Contributing Photographers:Tom GrowLeif LindbergLauri MattilaRobert PuhrRobert RyanJohann SbaschniggMartin SwayneTimo Vesterinen

Pictures on pages 4-7 courtesy of Zellstoff Stendal

Graphic Design:Morrison Graphic [email protected]

3 Pulp & Paper

4 Lighthouse in the EastZellstoff Stendal starts up greenfield mill

8 Modernizing to face competitive challengesNanping Paper installs second DIP line

12 Energy savings without sacrificing pulp qualityBowater Newsprint reduces energy, enhances quality with RTS™

16 Largest in the worldNew mill features largest woodyard and pulp drying line

20 High quality chips at WisaforestChippers and service tools keep old woodyard up-to-date

24 Gold standard for speedAPP’s Suzhou mill produces premium tissue at highest speeds

28 News from the world of Andritz

You will see the use of both “tonnes” and “tons” in this publication: tonnes for metric unitsand tons for American units. Unless otherwise noted, metric units are used.

Copyright © Andritz AG 2005. All rights reserved. No part of this publication may be reproduced without permission of the publisher.

The greenfield Veracel mill underconstruction near Eunapolis inBrazil's Bahia state. The mill has adesign capacity of 900,000 admt/aof bleached eucalyptus marketpulp and features a completeAndritz fiberline — from digesterto finished pulp bales — as well as an Andritz white liquor plant.

Issue 1 — 2005 FiberSpectrum 3

As this issue of FiberSpectrum goes to press,we are in the midst of the start-up of thegreenfield Veracel market pulp mill in Brazil.We are confident Veracel will be anothershowcase of our "full-line" capabilities fromdigester to finished bales of market pulp.

Full-line supply

Andritz's full-line approach and highly reliableequipment are clearly preferred by customersseeking reliable and proven equipment for thewhole mill and a unified approach to the design,documentation, training and start-up. Thesecustomers benefit from a minimum number ofinterfaces which simplifies project execution.Combined with the IDEAS simulation technolo-gy, this results in the fastest start-ups.

In Chile, we will deliver on an EPC basis acomplete Fiberline as well as chemical recov-ery systems for CMPC's new Line 2 at SantaFe. When completed in 2006, the line will pro-duce 780,000 t/a of market pulp.

In India, we will supply a new fiberline,recovery island, and woodroom upgrade forAPPM's Rajahmundry mill. With this invest-ment, APPM will increase pulping capacityfrom 300 to 550 bdt/d. Start-up of the newline will be in spring 2006.

Marusumi, one of Japan's biggest newsprintproducers, ordered an Andritz fiberline andchemical recovery systems for the Ohe mill.The new line will produce 252,000 t/a. Start-upis scheduled for the second quarter of 2007.

As our latest success, we received a letterof intent from Metsä-Botnia for Andritz to sup-ply the major processlines — wood han-dling, fiberline, pulpdrying and baling, andchemical recovery —for a greenfield pulpmill (1 million t/a) tobe built near FrayBentos in Uruguay.

World-class production

In May, the Andritz pulp drying line at Jiang Lin(see article on Page 16) set a world productionrecord of 3285 admt/d. This surpassed theguaranteed production level of 3250 admt/dand the previous record set at Aracruz in Brazil(2756 admt/d). This performance and highavailability of equipment is what mills expectwhen they choose Andritz.

Our new goal is to design and deliver a4000 t/d pulp line. We are simplifying designsand standardizing system modules whilemaintaining high product quality standards.Modularization allows us to reduce engineer-ing and manufacturing costs somewhat, and"freeze" the engineering sooner. This resultsin faster delivery and a lower overall invest-ment cost per ton.

The same applies to the world record pro-duction speed for tissue machines achievedon Andritz deliveries to China and Indonesia.

R&D

The end of April saw the official opening of theFiber Preparation Pilot Plant in Graz. Pilotplants play an important role in developing andselling process equipment. The Pilot Plantsimulates the complete recycled fiber processfor deinked, OCC pulp as well virgin fiberpreparation. It can be used for trials on singleunit equipment or for a complete system.

Our thanks to customers who have joined us indeveloping new unit machines and systems —particularly the Papillon™ refiner , the first

1000 t/d dispergingsystem, andSelectaFlot™ flota-tion. New productsdeveloped jointly withcustomers are thelifeblood of our R&Dprogram. We appre-ciate customers whoare willing to take thenext steps together.

Markku HänninenHead of Pulp Mill [email protected]

Bernhard RebernikHead of Paper Mill [email protected]

A message from Andritz P&P Management

Pulp&Paper

Lighthouse in the East: a newlife for pulping in Germany

German Chancellor Gerhard Schröder called it "Ein Leuchtturm im Osten"(A lighthouse in the East) when he attended the inauguration ceremonyfor Zellstoff Stendal's greenfield pulp mill. Built in the state of Saxony-Anhalt, in the former East Germany, the Stendal mill has the capacity toproduce 552,000 t/a of softwood market pulp. Andritz's contribution to this"lighthouse" is the recovery boiler, recausticizing and evaporation plant.

M e r c e r I n t e r n a t i o n a l

The trend towards large packages andsingle-line systems continues. Andritz'scapabilities in providing these largepackages is being demonstrated in

China, Chile, Brazil, Finland, India,Japan — and also recently in Germany.

Germany? Though it has not previ-ously been thought of as a chemical


German Chancellor Gerhard Schröderattended the inauguration ceremony forthe Zellstoff Stendal mill. The greenfieldproject became the biggest constructionsite in Sachsen-Anhalt state in Germany.

pulping region, the pulping landscape ischanging thanks to Mercer International(see box). Aided by the fact thatGermany has a more-than-adequatefiber supply, is looking for meaningfulinvestments (particularly in the East),and has seen the environmental relia-bility of the Rosenthal kraft pulp mill(also a Mercer project), the climate wasright for a greenfield project.

The new Stendal mill started up in

July 2004. Prior to Stendal, Mercerdecided to buy the Rosenthal mill, withits existing infrastructure, and modern-ize it. Rosenthal was changed from topto bottom. The sulfite process was con-verted to sulphate. Andritz deliveredthe entire chemical recovery island,modified the continuous digester, anddelivered major parts of the pulp dryingline. The mill produces 310,000 t/a ofsoftwood market pulp.

After the success at Rosenthal,momentum began building for thegreenfield Stendal project. With financ-ing in place, approx. EUR 1 billion,Zellstof Stendal, with its major share-holder Mercer International, awardedthe execution of the turnkey EPC con-tract to a subsidiary of German electric-ity giant RWE. The contractor, RWEIndustrie-Lösungen GmbH (RWE IN),broke ground in August 2002.


Andritz provided the major chemical recovery systems for the Stendal mill — evaporators, recovery boiler,and recausticizing equipment.

Project completed on schedule

Less than two years after the contractsigning, production at the Stendal millstarted up exactly as scheduled — onJuly 26, 2004.

"The expectations with regard to thisstart-up were high," says KristerSannholm, head of the Stendal project

group. "This was an important projectfor Mercer. Remember that the compa-ny started by purchasing a few smallpaper machines and then took the risksto become one of the world's biggestproducers of long-fibered pulp.

"In spite of the complicated contrac-tual structure we had, the project wascompleted within schedule, and we hada relatively smooth start-up of the mill."

Jimmy Lee and Mercer

The presence of Mercer International inthe center of the European pulp marketis a rags-to-riches story. MercerInternational is an American-Canadiancompany that was formed about 10years ago. Before acquiring theRosenthal mill and building the Stendalmill in Germany, Mercer only owned afew small Central European specialtypaper mills.

Today, Mercer International is one ofthe world's largest publicly traded pro-ducers of Northern Bleached SoftwoodKraft, with annual production of approxi-mately 1.3 million tonnes. Nearly 900,000tonnes come from Germany — whichis about 65% of the total pulp capacityin Germany. Mercer's remaining pulpcapacity comes from the recentlyacquired Celgar pulp mill in BritishColumbia, Canada.

The key strategist and operatingchief of Mercer is Jimmy Lee, 47, achemical engineer by training. Beforejoining Mercer International, Jimmy Leeclimbed the ladder in a financial institu-tion, first as a Director, and later asPresident. He has served as a trusteeat Mercer since 1985.


The evaporation plant is built in six effects, with a total capacity of 670 tonnes of waterper hour. In the evaporators, black liquor is concentrated to 75% dry solids beforeburning in the recovery boiler. An integrated stripper, methanol liquefaction system,calcium deactivation system, pressurized heavy liquor system are all included.

The capacity of the recausticizing plant is 8000 m3 of white liquor per day. X-Filters™reliably provide very clean green liquor for further processing. Dregs are washed and dried with a DreX-Filter ™ for a clean environment. White liquor is filtered with a CD-Filter™ providing less than 20 mg suspended solids per liter.

"This was a little different situation forus since our primary customer for theproject was the contractor RWE IN,"says Ari Nieminen, Project Director forthe Andritz delivery. "Most of the timewe work directly for the mill owner. Inthis case, we had a customer for theproject and a customer for the on-goingoperation and maintenance.

"It was very important for us to main-tain good contacts with both RWE INand the Stendal organizations duringproject execution. In the future, our rela-tionship will be more with Stendal direct-ly since they are operating the process-es and maintaining the equipment."

Andritz provided the equipment forthe evaporation plant, chemical recoveryboiler, and recausticizing plant. Also,Andritz supervised the erection andcommissioning work on the evaporationplant and recausticizing plant which wasconducted by RWE IN. Andritz tookresponsibility for the recovery boilererection directly.

"The cooperation between Andritzand RWE IN worked well throughoutthe project and we ended up in a suc-cessful and on-time start-up," saysNieminen. "In fact, we were readyahead of schedule."

The capacity of the recovery boiler is 3250 tds/d. The AndritzVertical Air™ system ensures optimal burning conditions andminimum emissions. Weak odorous gases and vent gases areburned in the recovery boiler.


Krister Sannholm, head of the Stendalproject group.

Find out more at www.fiberspectrum.andritz.com


Modernizing to face competitive challenges

Nanping Paper is one of the leading newsprint producers in China. Ithas enjoyed the benefits of strong growth in domestic consumption driv-en by the two decades of reform. But with reform comes challenges inthe form of competition and fiber supply. Andritz will continue to be animportant partner as Nanping meets the challenges head-on.

N a n p i n g P a p e r

Nanping Paper is one of China's ninetraditional state-owned newsprint pro-ducers. From their beginnings in the1950's to the late 1980's, these millsused domestically-manufactured papermachines. Workforce levels were veryhigh and productivity low. Each produc-er dominated its home province or region.Life was predictable and secure.

With reform comes competition

In the early to mid 1990's, the new eraof economic reform and trade liberaliza-tion saw the trickle of newsprint importsinto China turn into a flood. The importswere not only a threat in terms of vol-ume, but they were superior in quality.

Foreign investors moved to invest inworld-class newsprint capacity nearShanghai. In addition, new domesticcompetition began to emerge. Some ofthese players were newer enterprisesunder private or collective ownership,giving them the advantage of low work-force numbers while Nanping continuedto carry the burden of 3000 workers.

The reforms also had a positiveimpact for newsprint makers likeNanping. Improved living standards,and a new spirit of consumerism inChina, created a surge in newsprintdemand. The tired old format of existingnewspapers was revitalized by colorprinting, increased pagination, andsupplements. New publications cateringto a variety of Chinese readers began to emerge.

The new FibreFlow® Drum pulper at Nanping has a capacity of 320 t/d.

China's bold economic reforms

have revitalized newspaper

publishing, bringing a burst of

color, increased pagination,

and new titles. Nanping Paper,

the leading newsprint producer

in Fujian province, has taken

advantage of these reforms.


Time to modernize

Production at Nanping started in1958 with "100 tonnes per day ofnewsprint output from two 3.15 meterwide domestic-made machines," saysMr. Ye Shicheng, Chief Engineer.Publishers throughout Fujianprovince in southeast China made upthe home market.

Initially, Nanping used virgin fiberexclusively — groundwood and mar-ket kraft. The mill added its ownbleached kraft line in 1966. In the1980's, the addition of two locally-made paper machines boosted totaloutput to 150,000 t/a — still based oncostly virgin fiber.

Fiber supply, an issue for the millsince its early days, is still a "mainconcern," says Mr. Chen Shou Qin,President of Nanping Paper. Likemost papermakers throughout China,Nanping faces the difficulty of sourcingsufficient fiber at a reasonable cost.The only way to meet both the com-petitive threats and new market oppor-tunities was to invest and modernize.

In 1998, Nanping made a majorinvestment in a modern 6.1 meterwide paper machine, PM5. Themachine started up the followingyear, adding around 200,000 t/a.The mill took this opportunity to retireolder capacity — giving Nanping itspresent capacity of 295,000 t/a ofnewsprint. The investment not onlymade Nanping one of China's largestnewsprint producers, but it alsobecame one of the most advanced.The deinking projects that followedhave kept Nanping in its current low-cost, high-quality competitive position.

New sources of fiber

Investments in new fiber processingfollowed soon after the new papermachine started up. In July 2000, the

mill ordered a 500 t/d two-loop deink-ing plant (DIP) from Andritz and aFibreFlow® drum pulper fromAhlstrom Machinery (now part ofAndritz).

Nanping and Andritz workedtogether closely in engineering,equipment erection, commissioning,start-up, and system optimization,says Mr. Ye Shicheng. "The technicalstaff from Andritz and the mill workedtogether well during this period," hesays. Extended basic engineering forthe line was carried out by Andritz,while Nanping did the detailed engi-neering for the project.

Start-up of the deinking line occur-ring in mid-2001 meant the millcould efficiently substitute large vol-umes of lower cost, deinked second-ary fiber in the furnish. This was animportant achievement for Nanping,as it meant that the mill could "grad-ually move away from groundwoodand kraft pulp," and switch to "morethan 70% DIP, and part TMP," saysMr. Ye Shicheng.

He also noted that "the quality ofour newsprint improved steadily" fol-lowing the use of DIP from the newline. Nanping was also able to intro-duce lower grammage (45 g/m2)newsprint into the Chinese market,thereby strengthening its competitiveposition, Mr. Ye Shicheng added.

Second DIP line from Andritz

Following the success of the 500 t/dDIP plant, Nanping wanted to furtherdrive down raw material costs whileimproving newsprint quality. In 2003,mill management decided to replacean outmoded 100 t/d deinking linewith a larger, more modern DIP line.

Nanping again selected Andritz asthe supplier. The "good cooperation"and opportunity to use some systems

The Fiber Expert Forum included atour of Nanping Paper, with severalAndritz experts on hand to give visit-ing papermakers a detailed explana-tion of important features of the new300 t/d DIP line.

Nanping Chief Engineer, Mr.Ye Shicheng."Good technology and good coopera-tion led Nanping to again select Andritzfor a deinking line."

Global fast food chains have even reachedremote Nanping city. Western food is justone of the many lifestyle changes thatreforms have brought to China.

on the existing line werethe reasons behind thisdecision, says Mr. YeShicheng. This time, themill opted for a 300 t/dcapacity line.

Technical teams fromNanping and Andritz hadto overcome various diffi-culties during the engi-neering phase of the proj-ect, including the out-break of the SARS epi-

demic in China. The space constraintwas another issue, as Nanping had setthe limited area of the old line as thelocation for the new line. Andritz over-came this by creating a customizedflotation cell layout. The stacked designof the SelectaFlotTM flotation cell was anadvantage in this design process.

According to Mr. Ye Shicheng, thetechnology, project management, andimplementation were world-class on theproject. Nanping started up the newline just 96 days after the shutdown ofthe old deinking line — with the newline coming on-stream in January 2004.

Another success

Like the first DIP line, the new 300 t/dline was a milestone in the history ofNanping Paper. During trial runs of thenew line, the Andritz team workedtogether with Nanping and "carefully andcompletely optimized the system," saysMr. Ye Shicheng. "Output and qualityhave reached expected targets, andstock from the line has been used to pro-duce high quality newsprint," he says.

Following the DIP line investments,Nanping is now able to further boost thedeinked pulp content of its papermakingfurnish. "We now use 80% DIP and20% mechanical pulp", explains Mr. ChenShou Qin. "The high cost of electricitymakes production of mechanical pulpexpensive. Reducing our dependenceon virgin fiber while producing a qualitysheet keeps our costs to a minimumand positions us well to compete."

Expansion plans

Mr. Chen outlined Nanping's current plan-ning for a major greenfield investment."Why not expand operations at the pres-ent site instead?" says Mr. Chen. Hewent on to explain the rationale for agreenfield move.


Mr. Chen Shou Qin, President."Our cooperation with Andritz hasbeen friendly, honest, and successful."

The compact design of Andritz’s SelectaFlotTM flotation system was perfect forNanping’s new DIP line.

CompaDisTM disperser on the new DIP line.


"Nanping Paper is an advanced papermill with state-of-the-art paper machinesand deinking systems," says Mr. Chen."Technical renovation projects carriedout at the mill have been quite success-ful, leading to lower utility costs andfreshwater use than at comparable mills."

But the investments and technicalupgrading have been so successfulthat there is now little scope for furtherimprovements, Mr. Chen noted. Mean-while, the requirement to continue em-ploying a large workforce at the existingmill makes it very difficult to furtherreduce costs, he explained. "So, we

must set up a greenfield mill, and thisefficient new operation will help subsi-dize and support Nanping's overalloperations," he concluded.

Facing challenges

In summary, economic reforms havebrought nearly two decades of change forstate-owned players like Nanping. Whilethis change has brought the benefit ofnew market prospects, the newly compet-itive environment has made life tough forNanping. The mill has had to make con-

tinuous investments in order to remain animportant player in the newsprint game.

In addition, Nanping has to overcomequality issues in its RCF supply. Thereare certain to be more difficulties like this,as well as opportunities, in the yearsahead. Nanping's partnership with Andritzwill not only help Nanping to survive andprosper in the face of uncertainty andchange, but it will also help Nanping tomodernize and grow to meet new oppor-tunities, and to achieve further success.

KEY DATES FOR NANPING PAPERDate Achievements and milestones

1958 State-owned Nanping mill starts up with two locally manufactured paper machines and a groundwood pulp line (100 t/d newsprint capacity).

1966 Bleached kraft pulp line starts up (140 t/d pulp capacity).

1982 PM3 and PM4 start up and 150 t/d groundwood line (later retired) comes on-stream.

1988 PM1 and PM2 rebuilt, followed by PM3 and PM4 in 1992.

1996 New 200 t/d TMP line comes on-stream.

1999 Modern 6.1 meter wide PM5 starts up. Mill retires some old capacity.

2000 Nanping installs new Andritz 500 t/d deinking line which starts up in 2001.

2002 Further rebuilds of PM3 and PM4 boost newsprint capacity.

2003 Nanping decides to expand deinking and again chooses Andritz.

2004 New 300 t/d deinking line comes on-stream just 96 days after closure of old line.

2004 "Andritz Fiber Expert" symposium held at Nanping attracts 60+ papermakers from across China.


"We are not going to sacrificequality for energy savings."

B o w a t e r N e w s p r i n t

Bowater Newsprint's Calhoun, Tennesseemill in the USA is one of the largest pro-ducers of newsprint in North America. Itproduces 900,000 adst/a of pulp andpaper products — 490,000 tons of news-print, 250,000 tons of specialty grades,and the remainder as hardwood kraftmarket pulp.

The mill has had extensive experience

operating a conventional TMP plant. Builtin 1979 and expanded in 1985, the TMPplant (now Lines 1-6) consisted of Andritz(Sprout-Bauer) double-disc refiners witha production capacity of 1100 admt/d.

"In 1997, we began to talk seriouslyabout a project to establish Calhoun asa world-class facility with lower produc-tion costs," says Joe Vaughn, Pulping

Operations Manager, who is responsiblefor wood processing and fiber process-ing at the mill. "We wanted to installadditional TMP capacity so we couldshutdown our old groundwood mill andmodernize our woodyard. This wouldgive us better fiber for newsprint produc-tion, less kraft in the sheet, and woulddrive our manufacturing costs down."

The RTSTM Plant at Calhoun is designed for 814 adst/d, but routinely produces over this amount. "The pulp quality immediately —from day one — exceeded the quality we were getting from our conventional TMP plant," says Joe Vaughn.


When it comes to power consumption, the mechanical pulp mill is a major consumer (2500-3500 kWh/t). In atypical TMP operation, less than 10% of the energy goes into separating and preparing the fibers — 90% goesto steam. Andritz introduced RTS™ mechanical pulping technology in 1996, which decreases total refiningenergy from 15%-30% while producing competitive pulp quality in all respects. In 1997, Bowater Newsprintmade the decision to install RTS™ technology. Energy costs are down and pulp quality is excellent.

Bowater was willing to try somethingdifferent for this modernization project.Since they were moving from a relative-ly low energy consuming process(groundwood) to a higher energy con-sumption process like TMP, they did notwant to incur any more energy coststhan necessary. "But we would neversacrifice pulp quality just to get theenergy savings," Vaughn says.

Bowater decided to take a hard lookat the Andritz RTSTM technology becauseof its energy savings opportunities. In1997, there were few places Vaughn andhis team could go to see RTSTM operat-ing — and none that were runningRTSTM on pine.

"The big question for us was whatwould be the impact of increased refin-ing intensity on Southern Pine?"Vaughn says.

Andritz was developing its RTSTM tech-nology to make the fiber more resilient tohigh intensity refining. "We went throughan extensive evaluation process, visitingmills in Europe, Canada, and the USA,"Vaughn says. "We did a lot of pilot plantwork with Andritz. We came to the conclu-sion that RTSTM would give us the biggestopportunity for achieving the best overallresults — in terms of quality and energy."

The RTSTM Project

The RTSTM plant (Lines 7 and 8) startedup in July 1999. It was designed toproduce 814 adst/d of pulp.The primary and secondaryrefiners are Andritz Twin 66'spowered by 34,000 hp motors.The reject refiners are AndritzSB 170's and are powered by24,000 hp motors.

"We designed the plant withthe intention of RTSTM working,but we also found ways to miti-gate the potential risk if it didn'twork on Southern Pine," Vaughnsays. "Motor sizing was one ofthose decisions we made in thedesign phase to be able to switchback to TMP mode if needed.The motors are sized for conven-tional TMP and we are not com-ing close to utilizing all the horse-power capacity with RTSTM."

The evolution of RTS™

RTSTM is a modified TMP processpatented by Andritz. The R standsfor retention. T is for temperature.S is for speed.

Refining intensity increases withhigher rotational speeds — but sim-ply increasing the speed of a refinerdoes not result in higher qualitypulp. In fact, it can have negativeconsequences — reducing strengthand darkening the fibers due to thehigher heat generated.

The breakthrough in RTSTM camefrom pilot plant studies within Andritzthat uncovered a "window of opportu-nity" where the physical strength andoptical qualities of TMP pulps couldbe stabilized even though the fiberswere subjected to higher tempera-tures, pressures, and speeds.

Savings in electricity from RTSTM

(compared to conventional TMP)will surpass four billion kilowatthours in 2005 — representing overEuro 120 million.


Gordon Thom, Mechanical Pulping Superintendent (left), and Joe Vaughn, PulpingOperations Manager, at Bowater Newsprint's Calhoun, TN mill in the RTSTM plant.

The first-stage Twin 66 RTSTM

refiners at Bowater have demon-strated energy savings of 18-19%

while producing pulp exceedingthe quality of the old TMP plant.

"Andritz is very focused on our suc-cess here," says Gordon Thom,Mechanical Pulping Superintendent."They believe in RTSTM technology, aswe do, and they know it has a lot ofpotential. The RTSTM plant was designedfor 814 short tons per day, and we rou-tinely run about 17-20% over that."

"It was just a great start-up," saysVaughn. "The whole project was very wellorchestrated. From the moment we start-

ed up Line 7, we made 24 hours of con-tinuous production without a shutdown."

Bowater actually started up theRTSTM plant with Line 7 in conventionalTMP mode and later migrated this lineto RTSTM. For about a year, the milloperated with RTSTM on Line 8 andTMP on Line 7. This allowed them todirectly compare the energy savingsand pulp quality of the two lines usingthe same mechanical equipment.

"There was a give-and-take periodwith Andritz during the first year," saysThom. "We had to go through a platedevelopment program and other thingsto optimize the RTSTM plant."

Plate Development Program

"We've run different plates over theyears, but predominantly they havebeen Durametal®," Vaughn says.

"Immediately, we went to pretty goodlevels of plate life on the primary andreject refiners," Thom says. "Over thesummer, Andritz helped us implement anew automatic plate gap control andsupplied new plate patterns. We effec-

tively doubled our secondary plate life,which is important to us. Primaries lastfrom 1000-1200 hours, secondariesabout 1000 hours, and rejects about1200-1400 hours."

The Results — No Compromises

"We were fortunate in that, when weput the RTSTM plant in, we had an exist-ing TMP plant against which we couldbenchmark," Thom says. "We routinelylook at the performance of RTSTM ver-sus the older TMP lines. I can tell you

Andritz provided the major equip-ment for Bowater’s North andSouth log lines at Calhoun. As partof the modernization project, whichwas completed in 1999, Bowaterinstalled this portal crane. Withits 650-ft rail and 35-ton grap-ple, the crane serves as a loginventory organizer andloads the PowerFeedTM

conveyor to the Andritzdebarking drum.

The configuration at Calhoun enables the mill to directly compare energy savings andpulp quality between RTS™ and conventional TMP. Specific energy consumption isreduced an average of 18.5% with RTS™. Tear, tensile, scattering coefficient, andbrightness are all equivalent to conventional TMP.


that the energy reduction is there year-round and the pulp quality from theRTSTM plant exceeds the quality we getfrom the TMP plant."

"The RT pretreatment system reducesextractives content and the reject rate ishigher on the new lines," Vaughn says."Since start-up, we've optimized aroundthroughput and pulp quality, and we'vehad no significant issues with availability

of the equipment." "The performance of the refiners has

been very solid," Thom says. "Themainline Twin 66 refiners are veryrobust. The SB 170 reject refiners arevery stable and solid performers. Theyrun day-in, day-out."

In August of 2004, the mill began todetect a shift in raw materials and wasreceiving more juvenile wood. "So, we

decided to experiment and take the gear-box out of Line 7 to see if lowering therefining intensity would improve pulp qual-ity," Thom says. "Our experiment con-firmed that pulp strength properties werepreserved when refining juvenile woodwith RTSTM technology." The gearboxwas reinstalled on Line 7 primary refineron January 24 of this year and both linesnow operate using RTSTM technology.

Energy Reduction

"We're fortunate to have stable, competi-tive energy pricing in this area," Thomsays, "though energy prices today aremore significant than they were in 1999."

"It depends upon the season and theraw material, but our energy savings withRT pretreatment and RTSTM refining is inthe range of 15-25%," Vaughn says."When you talk about energy reduction,you have to be careful. The quality ofpulp a mill desires will dictate the amountof energy reduction it can achieve."

The conventional TMP plant at Calhoun produces about 1100 adt/d of pulp usingAndritz (Sprout-Bauer) double-disc refiners. The plant was installed in 1979.



Gordon Thom (left) talks with operators in the TMP control room.

The largest single-linepulp drying plantworldwide

The Jiang Lin pulp mill on HainanIsland is the first that Asia Pulp & Paper(APP) has built in China. The new millwill supply pulp to several APP papermachines in China, including somedestined to be built on the island,according to Mr. Liu Han Hung,President and Director.

Raw material for the mill will eventu-ally come from harvesting eucalyptusplantations on the island. "From 2008onwards, the plantations will be of thesize to supply the mill's total require-ment, making us self-sufficient," Mr. Liusays. "But, at present, our pulpwood is

being harvested from the Hainan,Guangdong, and Guangxi provinces."

The Jiang Lin mill started up inDecember 2004. According to Mr. Liu,the mill progressed from planning to com-pletion very rapidly. "Our original sched-ule was 18 months, but the actual time ittook to complete the project from turningthe first soil on the mill site was 18.5months, an impressive accomplishment."

Andritz delivered major packages tothis ultra-modern pulp mill, including thewood processing facility and the world'slargest single-line pulp dewatering/dry-ing/baling plant.

Pulp mill on the "Oriental Hawaii"

The Jiang Lin mill is located in theYangpu Economic Development Zone(EDZ) on Hainan Island.

The Chinese government is develop-ing Yangpu as an international centerto distribute processed products fromits freight-handling port, to takeadvantage of its location in the corearea of the Asia-Pacific sphere.

Yangpu was badly hit by the finan-cial crises that swept Southeast Asiafrom 1995 to 1998. Now, with therapid economic growth in China,the zone has entered a period ofsignificant economic recovery.

Jiang Lin created an economicboom in Yangpu. During spring2004, there were some 8000workers on site. When in fulloperation, the mill will employabout 1000 people.

Hainan now has a populationof 7.1 million people, of whichabout one million are ethnicminorities. It is the largestisland and the smallest landprovince in China. The naturalbeauty of the island has gained agood reputation among visitorsand it has been referred to as"the Oriental Hawaii."

"Both Hainan and Yangpu arein a period of transformation,"says Mr. Chi Fulin, President of theHainan Reform and DevelopmentAcademy. "Hainan is becoming animportant processing base for naturalgas. Investors are once again turningtheir eyes to Yangpu. It is the firstarea in Hainan to operate e-businessand e-banking services."

A s i a P u l p & P a p e r

The Andritz pulp drying line at Jiang Lin has a design capacity of 3250 admt/d at 250 m/min. Wire width of the pulp machine is 9.9 m. In May 2005, the plant set aworld production record of 3285 admt/d.


Some of the largest process equipment in the world, including a com-plete woodyard and pulp dewatering/drying plant from Andritz, is nowoperating on this island.


Gigantic woodyard

The Andritz wood processing facility atJiang Lin is the world's largest singlewoodyard, according to Matti Salmi, SalesManager for Andritz's Wood ProcessingDivision. The woodyard is dimensioned tohandle 1160 m3/h of solid wood (eucalyp-tus logs debarked in the forest). There arefour wood receiving and chipping lines.

"We received the order from APP inJanuary 2003 and had the woodyardoperational in October 2004, twomonths before digester start-up," Salmisays. "We have had an excellent rela-tionship with APP since the early 1990'swhen they ordered two complete wood-yards from us. They know that ourequipment will perform as promised,and we have learned how to processthe eucalyptus logs very efficiently."

Each chipping line consists of aFeeder Deck, conveyors, and a gravity-fed HQ-Chipper™. There are metaldetectors, stone traps, bark separationequipment, and a washing station — allto remove debris, sand, and clay arriv-ing with the incoming wood.

"The Feeder Deck at Jiang Lin is a newtype of receiving and feeding system forincoming logs," Salmi says. "It operateswithout conventional conveyor chains andrequires less maintenance. Capacity ofthe deck can be controlled automatically."

HQ-ChippersTM produce very highquality chips at high volume — evenfrom small diameter wood now availableat Jiang Lin. The chipping geometryensures stable log feed. The gentleside discharge of chips retains the chipquality — thin, long, and square — idealfor Jiang Lin's cooking process. Rejectrates at the digester, a critical indicatorof chip quality, are extremely low.

Chips are stored in two open chippiles. Each pile has a volume of150,000 loose-m3. The Andritz convey-ors can accommodate 8000 loose-m3/h.Four long CantiScrewsTM under eachchip pile reclaim the chips and movethem to the chip screening system.

The JetScreenTM is new Andritz technology which uses air to separate the chip fractions.The JetScreenTM at Jiang Lin is the world’s largest.

Eucalyptus chips are stored in two open chip piles, each with a volume of 150,000 loose-m3.

The Andritz chipping plant consists of four lines of HQ-ChippersTM which ensure idealchip quality for Jiang Lin’s cooking process.

Chips are screened with the new tech-nology JetScreenTM thickness screeningsystem. "This is our newest technologyfor chip thickness screening," Salmisays. "The unit is also the largest in theworld at a capacity of 2800 loose-m3/h."In the JetScreenTM, dust, fines, over-sized and overthick chips are separatedfrom good chips with air impulses.

"There is an extremely small percent-age of wood loss with the HQ-ChipperTM

and JetScreenTM," Salmi says. "Lossdue to fines is about 0.7% and loss dueto pins is 0.5-1%."

Overthick and oversize chips are sentto an HQ-SizerTM for processing so theycan be recovered for the cookingprocess. Fines and dust are mixed withbark and used as bio-fuel in the powerboiler. The water treatment system inthe woodyard and the process controlsystem were also delivered by Andritz.

World's largest pulp drying plant

APP had previously installed Andritzpulp drying lines at their Perawang andJambi mills in Indonesia, according toMr. Liu. "The total investment costsand the previous experience we havewith Andritz's project and service exe-cution were the driving forces behindour decision to purchase from Andritzfor the Jiang Lin project."

The Andritz pulp drying operation isdesigned to produce 3250 admt/d ofbleached pulp at a design speed of 250 m/min. The pulp machine has a wirewidth of 9.95 m. Included in the Andritzscope is a screening system, Twin Wireformer pulp machine, a FläktTM dryer, theworld's largest cutter/layboy, and fourautomated baling lines.


The Andritz ModuScreen® sys-tem prior to the pulp machinehas a capacity of 4275 admt/d.The screens are arranged in afully-closed cascade to achievethe highest efficiency with lowestrejection of good fibers.

The Fläkt™ dryer uses heat-ed air to dry and support thepulp web. With the exceptionof the turning rolls at eitherend of the machine there areno moving mechanical partsinside the drying chamber.

The pulp machine has Andritz's advanced twin-wire forming technology.Dewatering in the press section is accomplished by a three-roll Combi-Press, followed by a double-felted shoe press.

Robert Rauchegger discusses automatedcontrol of the wrapping/baling line withMr. Hu YinJun of Jiang Lin.

Single-line success

"The Jiang Lin project is a significantstep forward in the single-line productiontrend," says Bernhard Rebernik, mem-ber of the Andritz Managing Board andresponsible for Paper Mill Technologies."We are currently providing large, sin-gle-line systems at Veracel in Brazil andCMPC in Chile based upon some ofour development work here. When you

shake hands with a customer on a proj-ect like this, you need to be certain thatwhat you will deliver is the best avail-able solution, since there are no back-up or duplicate systems."

Regarding the Jiang Lin project,Rebernik notes that, "It has been veryrewarding to work with APP as they arewilling to invest in technologicaladvances. The Andritz team workedvery well with the local engineers and

we have been able to source quite a lotof the project supply within China." Mr.Liu confirms, "The single fiberline is thefirst stage in our strategic planning.Having started up this first stage, weare now planning to install tissuemachines in an expansion of the mill."

Lower investment and operating costs

Through an intensive program of com-puter simulations and pilot work, Andritzdetermined that there are significantadvantages in a large capacity single lineoperation. "We show customers howthey can lower their investment cost perton of product by as much as 20%, aswell as lowering their operating costs,"Rebernik says. "This is when comparedto a two-line operation. Potentially, wecan go even higher in capacity."

The world's largest cutter/layboy receives the pulp web from the dryeras the web is slit and cut into bale or wrapper-sized sheets.

Pulp bales are pressed, wrapped, stacked four high, and tied togeth-er in two-ton units in the bale finishing line.


Finished bales are conveyed to the warehouse and are ready for dispatch.


Unique combination of technology and service helps Wisaforest producehigh quality chips in volume.

U P M

Located near Pietarsaari on the westcoast of Finland, UPM's Wisaforest millhas a capacity of 800,000 tonnes of pulpand 180,000 tonnes of paper per year.There are two separate cooking lines inthe pulp mill, fed by two different wooddebarking and chipping lines (one forhardwood, one for softwood).

"These lines started up at the end of1985," says Tero Virkkala, Pulp MillProduction Manager. "I think this wasthe very first Kone (now Andritz) drydebarking system in Finland. Comparedto a modern woodroom, it is naturallyshowing its age, but it performs as itshould be performing."

The two original chippers have beenupgraded to Andritz HQ-Chipper™models, and the bark press has beenchanged out. "But, through 20 years ofservice, all the other main pieces of equip-ment are the original ones," says Virkkala.

"This year, as pulp production isincreasing, we will debark and chip over3 million cubic meters of roundwood,"Virkkala says. "Such production fromtwo debarking lines is a great accom-plishment. I have to say that the Andritzchippers have been very good at achiev-ing the capacity and quality we need."

Three million cubic meters oflogs are chipped each year atUPM's integrated Wisaforest com-plex in Finland. The woodroom,now 20 years old, keeps up withthe demand for high quality chipswith the help of new chippers andtools developed by Andritz.


In spite of its excellent operation,Wisaforest's woodroom is nowapproaching the end of its lifecycle, according to Virkkala. "Weare contemplating whether to mod-ernize the main equipment or builda completely new woodroom. Untilthe decision is made and the workcompleted, we need to keep thewoodroom operating reliably andproducing high quality chips."

Wisaforest has implementedseveral innovative technologiesand services from Andritz toextend the life of the woodroomand ensure the smooth flow of highquality chips to the fiberlines.

Longer chips with HQ upgrade

As Virkkala says, “The center offocus in any woodroom is the chip-per.” Kenneth Winberg, Pulp MillManager at Wisaforest, agrees."Chipper operation is a matter of highpriority because it establishes thequality of chips produced. We cannotafford low quality chips or our cook-ing quality would be compromised."

The conventional single regrind-able knife system in the chippershad been reliable for many years,according to Virkkala. "But we nowknow that the best possible knife, interms of chip quality, is the thinnerHQ-Plus™ cassette knife system inthe HQ-Chipper™. It produceslonger, thinner, and more uniformchips, which improves the cookingprocess."

Before upgrading the chippers in1992 and 2001 at Wisaforest, theCarthage chippers produced chips22 mm in length. "With the HQ-Plus™ knife system in the chippers,we are close to lengths of 30 mm,"Virkkala explains. “Our hardwood linedelivers chip lengths of 28-29 mmand the softwood line 27 mm."

The main enemies of a chipperknife are stones and metals thatcome in with the wood. Theseitems can quickly damage or dullthe rotating knives inside the chip-per and lead to off-quality chips.

"With the old knife system, wehad to change knives even if theyreceived only minor damage,"Virkkala says, "because the chip-per capacity would drop off signifi-cantly. Now, the HQ-PlusTM knifegeometry is so good that a fairlyhigh capacity is maintained evenwith damaged knives or dullerblades."

While this was great for produc-tion, the good performance of theknife system might also maskpotential problems with the chip-per, according to Virkkala. "If weonly monitor production, we mightnot detect more serious problemssuch as a broken knife strikingagainst the anvil. We installed acost-effective way to monitor thecondition of the chipper knives andother wear parts in the chipper."

"Listening" to the chipper

Andritz's Automation & Diagnosticsgroup was supplying sensors todetect changes in the condition ofprocess equipment and pressurevessels for other areas of apulp/paper mill — so why not thewoodroom?

"When Andritz told us they haddeveloped acoustic emissionstechnology to monitor the condi-tion of chippers, we were veryinterested in trying it," Virkkalasays. "We wanted to improve thereliability of our chipping lines andstill keep the thinner cassetteknives of the HQ-PlusTM system.We felt that Acutest® technologycould help us do that."

HQ-PlusTM makes routine knife changes at Wisaforestan easy, safe, and quick operation – for the best pos-sible chipper availability.

"We cannot afford low quality chips or our cookingquality would be compromised". Kenneth Winberg,Pulp Mill Manager (left) and Tero Virkkala, Pulp MillProduction Manager at Wisaforest.


Acutest® acoustic emissions technol-ogy uses ultra-sensitive sensors to "lis-ten" for elastic waves generated when a material begins to deform, fatigue, or fracture. Acutest® systems are usedto detect problems such as the initiationand growth of fatigue cracks in steelstructures; the failure of bonds, fibers,and filaments in composite materials;and the appearance of potentially haz-ardous flaws in pressure vessels.

Operators watch "traffic lights"

The Acutest® system at Wisaforest con-tinuously monitors the chipping equip-ment and displays critical informationabout the knife condition. Any variationsfrom normal are displayed to the opera-tors in the form of a "traffic light" —green for good, yellow for caution, andred for alarm. The Acutest® system isdesigned to work with any open distrib-uted network where condition monitor-

ing measurements are a part of theprocess control system.

Kari Aura, Application and SalesManager for the Automation &Diagnostics product group, explains,"Three sensors are mounted on thechipper, at the front bearing, tail bear-ing, and gearbox. "In principle, wecould do it with one sensor, but the oth-ers give us more information for bettercontrol and also serve as a backup."

"If the knives are dull or in badshape, this is immediately shown onthe traffic light display in our controlsystem," Virkkala says. "If vibrationincreases, the operator gets an alarm.We have the possibility to add someautomatic interlocks to stop the chipperif certain limits are reached. The dam-aged knife, or other wear part, ischanged out."

With the Acutest® system, necessaryactions can be taken before a malfunc-tion occurs and before chip quality iscompromised. "It is even possible tooptimize chipper knife life because we

"Hearing aids" for yourprocess equipment

Andritz Services' Automation &Diagnostics group specializes indesigning and supporting specializedsensors, process control, and opti-mization systems for the pulp andpaper industry.

Part of the group's offering includesAcutest® systems which monitorprocess machinery and vessels to"listen" for potential structural cracks,leaks, vibration, fissures, and friction.

Acutest® systems use a technologycalled Acoustic Emissions Monitoring.Ultra-sensitive piezo sensors "listen"and record the amount of "elasticwaves" generated by rapid changes inthe microstructures of metals or com-posite materials. Potential problemssuch as friction or cracks can bedetected and monitored — typicallybefore they result in downtime for theequipment.

The systems are designed to beintegrated into open network distrib-uted control systems and can also be monitored remotely through anInternet connection.


The Wisaforest mill complex in Finland showing the wood processing operations.

know the correlation between theacoustic emissions and the wear on theknife set," says Aura.

"The Acutest® acoustic emissions sys-tem tells us the knife condition at anytime, so we have found a well-function-ing and reliable solution to our problem,"Virkkala says.

HQ-PlusTM Chipper Service agreement

A big contributor to uniform quality inthe chipper is optimizing the process ofchanging knives and other wear parts.The changes must be swift, reliable,and controllable.

"Pulp quality starts with chip quality,so we are not interested in settingworld records for the longest knife life,"Virkkala says. "During continuousoperation, we typically change knivesonce every 24 hours, or about 6000cubic meters of chips at best.Fortunately, the hydraulically operatedquick clamp mechanism in the HQ-PlusTM system allows for extremely fastknife changes."

Wisaforest utilizes Andritz's HQ-PlusTM

Service to keep the chippers operatingreliably and effectively — regrindingknives at regular intervals, and main-taining a stock of sharpened knives andcritical wear/spare parts at the mill. Aspart of the service, Andritz techniciansperform regular chipper inspections.

Remote link to Andritz

The Acutest® system at Wisaforest islinked remotely through the Internet toAndritz service centers in Tampere andHollola, Finland, according to JarnoKämäräinen, Andritz's ProductManager for HQ-Plus™ Service.

Summary reports and "traffic lights" are used at the mill. Andritz analyzesthe detailed data received and issues asummary report of chipper operationfor the mill.

Remote diagnostics can also discov-er irregular noise emissions from thechipper which should be investigatedby the mill or by an Andritz serviceengineer in order to find the cause.

"At the moment, we are developing abroader service package related to ourchipper HQ-PlusTM Service and Acutest®

monitoring," Kämäräinen says. "This willinclude special tailor-made options, includ-ing connecting other pieces of woodyardequipment such as debarking drums, feedequipment, and screens as necessary."

Chip analyzer for onlinequality control

The Acutest® system at Wisaforestgives information about the condition ofthe chipper knives. Andritz has alsodeveloped a new system to measureand analyze chip quality online.Wisaforest is one of the first installa-tions of this online chip sampler andanalyzer which displays continuousdata about chip quality to optimize thechipper operation.

"Fluctuating chip quality makes thecooking process extremely difficult tocontrol," Winberg says. "We expectthat this newest Andritz innovation willturn out to be a good tool for us."


Kari Aura (left), Application and Sales Manager for Andritz's Automation and Diagnosticsproduct group, and Jarno Kämäräinen, Product Manager for Andritz's HQ-PlusTM Service,team up to provide innovative tools such as remote diagnostics to help mills achieveexcellent chip quality, uniform quality, and reliable operation.


Gold Hong Ye Paper, owned by AsiaPulp & Paper (APP), operates a tissuemill near Suzhou, two hours drive westof Shanghai. The mill recently set astandard in making premium facial andtoilet tissue that could be a target fortissue producers around the globe.

Gold Hong Ye is producing high-gradetissue on a regular basis at the highestaverage speeds in the world.

Early last year, one of two Crescent

Former tissue machines supplied byAndritz to Gold Hong Ye (TM2) set aworld record of five continuous daysproduction of 13.5 g/m2 facial tissuerunning at 2100 m/min.

"We now regularly run our two mach-ines over 2000 m/min when makingpremium grade facial tissue and at1800 m/min on 18 g/m2 premium toilettissue," says the mill's ProductionManager, Mr. Y.T. Hsu.

No time to rest

"Still, we are not satisfied to rest onthese achievements," Mr. Hsu says."With the assistance of Andritz special-ists, we fully expect to improve the per-formance of our two machines, whichare almost seven years old."

The two machines supplied by Andritz"are very well engineered" according toMr. Hsu and "have proved to accord us a

Suzhou mill sets GoldStandard for speedChina, once considered a "developing" nation, has developed itstissue industry into a producer of high quality products. Shanghaioffers insight into one of the most modern cities in the world. A visitto APP's Suzhou mill, outside of Shanghai, offers a glimpse into amodern tissue production facility that operates two of the fastestmachines in the world.

G o l d H o n g Ye

TM2 is one of the two identical CrescentFormer tissue machines at Gold Hong Ye. Both machines have a trim width of 5.6 metersand run at the highest average speeds in the world.


* The current official world speed record for CrescentFormers is also held by an Andritz machine— at PT. Lontar Papyrus, Jambi, Indonesia (part of the APP Group). In December 2004, themachine ran 32 hours at a continuous speed of 2110 m/min (13.5 g/m2 facial tissue).

high degree of reliability and runability."The mill has made some upgrades andminor modifications to the machines dur-ing the first three years and "the wet endand dryer still perform as required."

"In the intervening years, technologyhas advanced and some modificationsto the dry end are necessary," Mr. Hsusays. "Andritz is cooperating with ourengineers to make the necessaryamendments. Threading and reeling arethe most critical points and where we getmost breaks. However, we still run two ofthe fastest tissue machines in the world."

The Andritz machines

The two machines at Suzhou areCrescentFormer designs, each with twopressure rolls. The ribbed Yankee cylin-ders have diameters of 5.5 m. Trimwidth of both machines at the reel is5.6 meters.

Following the start-up of TM2 inDecember 1998, performance testswere run for different tissue grades.Phase 1 optimization by Andritz techni-cal specialists included the installation ofPrimePickup™ in the former. After this,the first speed record of 2020 m/minwas achieved. In December 2003,Gold Hong Ye engineers carried outPhase 2 optimization by making somemodifications to the wet and dry ends

and releasing the maximum speed limiton the multi-motor drives. In January2004, a new world record speed* of2100 m/min was reached. TM1 alsoreached 2060 m/min producing 17.5 g/m²toilet tissue in January of last year.

Increasing efficiency

The mill generally uses TM2 for the pro-duction of facial tissue and TM1 for toiletgrades. "This means that TM2 is themachine that generally runs at higherspeeds," Mr. Hsu says. "If we assume100% efficiency is achieved at 2200 m/min,we average 92% efficiency for regulargrades and 85% on premium grades.Our target is to reach 90% efficiency inthe production of premium grades."

Mr. Hsu says there are improvements tobe made between the creping doctor andthe reel, and his engineers are workingwith Andritz in order to reduce dusting.

"We are using a conventional crepingsystem and this has the tendency tocause a significant amount of dust,especially with the shorter fiber andhigher softness of our premium grades,"he says. "With the new developmentsin technology, we expect to be able tocut down on the amount of dust creat-ed, and increase our machine speedsand efficiency.”

Years of experience in tissue

Y.T. Hsu has been involved in tissuemaking for some 30 years. He startedwith Scott Paper in Taiwan and movedto Kimberly-Clark. Seven years ago,he moved to the mill in Suzhou as aproject leader for the installation ofthe two Andritz machines. He workedhimself up to graduate level in themills as, at that time, there were noformal papermaking courses in theschools or universities of the region.

TM2 started up in December 1998.The second machine started inJanuary 1999. "We now employ grad-uates from mechanical and chemicalengineering courses for the moreskilled jobs in the mill," Mr. Hsusays, "but we have found the localpeople, who have no prior experi-ence in production, to be very quickto learn. Plus, they are immediatelyeducated into our way of thinking."

Mr. Hsu is looking forward to play-ing a major part in the team estab-lished to develop the new tissuemachines on Hainan Island in theSouth China Sea, off the coast ofGuangdong province.

(See page 16 for related story)


Additional machines?

Gold Hong Ye's engineering and produc-tion teams are undertaking de-bottleneck-ing projects around the machines, andare also looking to install new machineson Hainan Island, in the South ChinaSea. This island is the site of APP'snew large-scale pulp mill (see relatedstory on page 16).

"In our process we use only virginfibers as APP is a major producer ofchemical pulp," Mr. Hsu says. "The fur-nish is primarily eucalyptus and acaciahardwoods, but we also add a propor-tion of Northern softwood pulps."

Leading tissue brands in China

According to Mr. Hsu, Gold Hong Yeproduces the leading tissue brands inChina. The company is also able toexport a large proportion of its premiumgrades to countries with high qualitydemands in the Pacific region.

"It is important that we work in coop-eration with our suppliers and potentialcustomers to refine our products, inorder to meet their requirements in themost cost-effective way possible," hesays. "It is very important in the tissuemaking process to get the mix right."

Environmentally sound

The Suzhou mill complex, which incor-porates the papermaking facilities ofsister company Gold Hua Sheng, hasnow been certified to ISO 14001 envi-ronmental standards. The area aroundthe mill and Suzhou city is a network ofrivers, waterways, and lakes.

"It is important that the high pollutionlevels of some local paper producers inChina be reduced as quickly as possi-ble," Mr. Hsu says. "Our mill site has its

own treatment plant andwe are constantly movingtowards the minimumemissions to water and air,and the most efficient useof energy."

APP Group

Andritz's contribution to APP'sexpansion over the years:

1992•• Two 7.4 m wide pulp drying lines

for APP's Perawang facility and PT.Lontar Papyrus Pulp & Paper Industry, Jambi, Indonesia

1996-1999•• Two more 7.4 m wide pulp drying

lines for Perawang and Jambi

•• The 4th Andritz pulp drying line for Perawang

•• Four 600 t/d packaging board machines (two at Indah Kiat Pulp & Paper, Serang, Indonesia, and two at Ningbo Zhongua Paper, China) —order received in a consortium with Sulzer Escher Wyss

•• Four large tissue machines (one forPT. Pindo Deli Pulp & Paper Mills,another for PT Lontar Papyrus Pulp& Paper Industry (both Indonesia),and two machines for Chinese GoldHong Ye Paper

•• Stock preparation lines for Jiangsu Gold East Paper's Dagang, China mill

The latest Andritz installation for APPis a complete pulp dewatering anddrying line, as part of the world'slargest single-line pulp plant at HainanPulp & Paper, China, started up in late2004. (See page 16 for story)


Mr. Y.T. Hsu, ProductionManager at Suzhou (left)with Mr. Ted Chen,Executive Vice PresidentDirector, who is responsiblefor Gold Hong Ye’s tissuemill at Suzhou.

The area around Suzhou is anetwork of rivers, waterways,and lakes. Gold Hong Ye con-stantly works at minimizingemissions to water and air.

The site has its own power plant withelectrostatic precipitators to reduce fluegas emissions. Andritz has contributedto helping Gold Hong Ye reduce water

consumption. On average, the mill isdown to 9 m³ of water consumption perton of tissue produced. The target,according to Mr. Hsu is 8 m³/t. "Which is

not that easy since, with the machinesrunning faster, more cooling water isneeded," he says.

Mr. Hsu was very enthusiasticabout the cooperation with Andritz."We work together very well," he says."Compared to 10 years ago, machinebuilders have really focused on the tis-sue making processes and, in somecases, know more than the papermakerhimself. They understand the differentfibers, chemicals, and machine cloth-ings. And, they are learning how tokeep the costs down.

"We consider the new Andritzmachine to be one of the best. Andritzand our people have formed an excel-lent team and share knowledge on aregular basis. We know that if we facea problem, we can depend on theirquick technical support in order to helpus continue to operate at these veryhigh speeds."

The Suzhou mill produces some of the leading tissue brands in China. The company is also able to export a large proportion of itspremium grades to countries with high quality demands in the Pacific region.



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Chemical Systems


Veracel Celulose Eunapolis, Brazil White Liquor Plant, Recausticizing Plant and Lime Kiln EPC Delivery

Upgrades & Moderizations

Bahia Sul Celulose Suzano, Brazil Lime Kiln Retrofit

Pulp Drying & Finishing


Veracel Celulose Eunapolis, Brazil Sheet Drying Line 9.33 m Complete line from storage tower to finishedbales — one of the largest in the world

Mechanical Pulping


Dunaujvarosi Cellulozgyar Dunaujvaros, Hungary Flax Refining System New technology

Trombini Papel e Embalagens Fraiburgo, Santa Cata, Brazil HC Refining System for Kraft Sack Paper

M-real Joutseno, Finland Reject Bleaching System

Panelboard


Jiu Ke Song WBP Hubei Hubei, China Pressurized Refining System for MDF

Heze Chenming Panels Lindun Shandong, China Pressurized Refining System for MDF

Anhui Luzhou WBP Anhui, China Pressurized Refining System for MDF

Yunnan Jinggu Forestry Yunnan, China Pressurized Refining System for MDF

Henan Mengzhou WBP Henan, China Pressurized Refining System for MDF

Anhui Taihu County Board Jinchan Anhui, China Pressurized Refining System for MDF

Kronostar Scharja, Russia Pressurized Refining + Chip Washing System 1100 t/d MDF plant – highest capacity for onerefiner/chip washing line

Tever MDF Bölgesi, Turkey Pressurized Refining System for MDF

Fiber Preparation


Nanping Paper Nanping, Fujian, China DIP System for 370 t/d Newsprint Grades First complete line in China with new Andritz equipment

Start-ups

First 180 ft. radius circular crane started-up in October2004 at Weyerhaeuser, Oglethorpe, GA, USA

HC Kraft Sack Paper Refining, TrombiniPapel e Embalagens.

FS-Karton (Mayr-Melnhof Group) Neuss, Germany DIP System for 200 t/d for Top Layer of Board Machine First complete line including sludge dewateringin Germany

Al Sindian Paper Mill (Nuqul Group) Giza, Egypt Complete Stock Preparation for TissueMachine Andritz major supplier for new tissue mill

Shandong Chenming Paper Shouguang, Shandong, China Complete Paper Machine Approach System

Key Equipment

Smurfit-Stone Container Bathurst, QC, Canada and Matane, QC, Canada Coarse Screening Systems World’s largest recycler chooses Andritz’sunique technology which dramatically simplifies mill flowsheet and power costs

Norampac Cabano, QC, Canada TwinFloTM Refiner

M-real Hallein Hallein, Austria FilRecTM System First FilRecTM system in Austria

M-real Stockstadt Stockstadt, Germany FibreSolveTM Pulper

Pfleiderer Spezialpapiere Teisnach, Germany PapillonTM Refiner

Dr. Franz Feurstein Traun, Austria Five TwinFloTM Refiners

Norske Skog Bruck Bruck, Austria PapillonTM Refiner

Daehan Paper Cheongwon, South Korea Conveyors and FibreFlowTM Drum Pulper

Stora Enso Hylte Hyltebruk, Sweden FibreFlowTM Drum Pulper with Three-Stage Coarse Screening System

UPM-Kymmene Kaipola, Finland Fine Screening System, incl. ModuScreenTM

First start-up of big A-type screen

Tissue Machines


Thüringer Hygiene PapierWernshausen, GermanyPrimeLine™ Tissue Machine withTissueFlex™

Ventilation and DryingFor Tissue and Paper Machines

Key Equipment

Adolf JassSchwarza, GermanyPM Hood and Air Systems

M&D Impregnator from the new Sawdust Cooking Line at Wisaforest, Pietarsaari.Start-up was summer of 2004.


A N D R I T Z P U L P & P A P E R

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Visit FiberSpectrum Online at: www.fiberspectrum.andritz.com or the main Andritz site at www.andritz.com

F.2.a.3.15500.e.6.05

the customer magazine of andritz pulp & paper issue 12005 · the customer magazine of andritz...

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